Method of durably grafting decorated cotton fabrics to cotton cloths such as jeans with stencil

ABSTRACT

A meted of manufacturing a durably grafting decorated cotton fabrics to a cotton cloths, which is comprised of; first step of printing a pattern on a cotton fabric by a stencil, second step of pasting a glue solution of Polyone S11111 seriesone clear from Polyone Corporation, which contains 1 to 5% of fumed silica for inhibitor, on the rear side of the pattern on the cotton fabric, third step of overlapping the glue pasted cotton fabric over a clothes such as a blue jeans, fourth step of over-lapping the pattern containing stencil over the front side of the cotton fabric, fifth step of place the stencil and the clothes between a heating press and press for 5 minutes at 160° C. (320 F.), sixth step of pasting a burn out gel on the stencil, and seventh step of removing the left of burn out from the clothes. This technology can be other artificial fabrics. And all these procedure is done by just stencil and press.

FIELD OF THE INVENTION

Current application relates to a method of durably gluing grafting fabrics each other, especially relates to a method of durably gluing decorated cotton fabrics to another cotton cloths such as blue jeans.

BACKGROUND OF THE INVENTION

Jeans, blue jeans, became a heritage of human culture representing youth culture. They spread throughout the whole world and every youngster already has at least one of it or wants to have one. Now, jeans take a big portion in fashion industry. Recently, many kind of technologies are introduced to decorate jeans to meet requirements of young customers. However, due to the characteristics of the material, 100% cotton, method of decorating jeans are limited. Customers' requirement asking various different designs makes it more difficult. Printing might be the easiest way for decorating jeans with various designs. But, repeated washing deteriorates the drawings. Embroidering is the most durable and popular method of decorating the jeans. But, production cost for various designs is high. Gluing may be one of the cheap and convenient methods of grafting jeans with designed fabrics if it is durable. It is purpose of the current application to develop a method of durably gluing decorated fabrics to other cotton cloths such as blue jeans by applying much kind of materials as a gluing agent.

DESCRIPTION OF PRIOR ART

U.S. Pat. No. 5,758,588 to Orfali illustrates an applique such as a lace-trimming is grafted onto a region of a textile product, such as a towel or a pair of blue-jeans. Previously, said region is marked by lock stitching on the product base material by means of an embroidering machine and removed therefrom, preferably by cutting or punching in a press. The applique is then bridged onto the removed portion of the base material with only a small overlap thereover and joined thereto by embroidering a seam all the way round the overlap with the machine. The seam is preferably about 4 mm wide and the overlap between 2 mm and 3 mm. A method is disclosed wherein the product is permanently retained in a hoop between the marking and joining steps, through the removing step, thus enabling the product to be uniquely placed relative to the embroidering machine before and after temporary removal to the press.

U.S. Pat. No. 4,325,861 to Braun, et al. illustrates water-soluble polymers that are rapidly dissolved by employing a concentrate of (i) a water-soluble particulate polymer, (ii) a water-insoluble organic vehicle which is a non-solvent for the polymer, (iii) a nonionic surfactant agent having an HLB in the ranges of 3-5 and 9-13 and if necessary, and a thickening agent.

U.S. Pat. No. 4,860,387 to Williams illustrates a decorated garment (11) has a plurality of doll figures (12, 13, 14) mounted on its front surface. Articles of clothing (26) for each of the doll figures are adapted to be attached to the doll figures to provide decorative wardrobes for the doll figures.

U.S. Pat. No. 5,087,664 to Sugino, et al. illustrates a plastisol composition comprising a vinyl chloride polymer, a plasticizer and an adhesion-imparting agent, characterized in that the adhesion-imparting agent is a diisocyanate polymer blocked with an oxybenzoic acid ester or with an alkylphenol and having an average molecular weight within a range of from 1,000 to 10,000.

U.S. Pat. No. 4,156,678 to Krueger illustrates a thermosetting coating composition, of controlled rheology, of a urethane polymer that cures into a durable, flexible coating is the subject of this invention; the film-forming constituents of the coating composition are (1) an organic polyisocyanate, and (2) a polymer that has a backbone of polymerized ethylenically unsaturated monomers and has attached directly to its backbone ester groups of the following structure. (Branched Structure with R₁,R₂, and R₃) or an isomer thereof, wherein R₁, R₂ and R₃ are hydrocarbon radicals; and the rheology control agents are fumed silica, attapulgus clay, copolymers of acrylonitrile/methyl acrylate of high nitrile content, modified microgels and the like. This novel coating composition is particularly useful, especially when applied over zinc rich primers, as a high quality industrial finish and can be used to paint autos, trucks, aircraft, railway equipment and the like.

None of the prior art illustrates a method of grafting 100% cotton fabric onto 100% cotton cloths such as blue jeans to produced a glued cotton wear durable over 1,000 times mechanical washing.

SUMMARY OF THE INVENTION

Jeans, blue jeans, became a heritage of human culture representing youth culture. They spread throughout the whole world and every youngster already has at least one of it or wants to have one. Now, jeans take a big portion in fashion industry. Recently, many kind of technologies are introduced to decorate jeans to meet requirements of young customers. However, due to the characteristics of the material, 100% cotton, method of decorating jeans are limited. Customers' requirement asking various different designs makes it more difficult. Printing might be the easiest way for decorating jeans with various designs. But, repeated washing deteriorates the drawings. Embroidering is the most durable and popular method of decorating the jeans. But, production cost for various designs is high. Gluing may be one of the cheap and convenient methods of grafting jeans with designed fabrics if it is durable. It is purpose of the current application to develop a method of durably gluing decorated fabrics to other cotton cloths such as blue jeans by applying many kind of materials as a gluing agent. A method of manufacturing a durably grafting decorated cotton fabrics to a cotton cloths, which is comprised of; first step of printing a pattern on a cotton fabric by a stencil, second step of pasting a glue solution of Polyone S11111 seriesone clear from Polyone Corporation, which contains 1 to 5% of fumed silica for inhibitor, on the rear side of the pattern on the cotton fabric, third step of overlapping the glue pasted cotton fabric over a clothes such as a blue jeans, fourth step of over-lapping the pattern containing stencil over the front side of the cotton fabric, fifth step-of pasting a burn out gel on the stencil, sixth step of place the stencil and the clothes between a heating press and press for 5 minutes at 160° C. (320 F.), and seventh step of removing the left of burn out from the clothes. All these procedure is done by just stencil and press.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1-1 is a schematic drawing of method of producing a patterned stencil of prior art.

FIG. 1-2 is a schematic drawing of prior art of printing method utilizing stencil.

FIG. 1-3 is a schematic drawing of method of prior art producing a patterned fabric grafted clothes utilizing a stencil of prior art.

FIG. 2 is a schematic drawing of gluing and grafting of cotton fabrics to a cotton clothes according to current application.

FIG. 3 is a cross sectional view of stencil, fabric, cloth, and support overlapped to produce cotton fabric grafted cotton cloth.

FIG. 4 is a schematic drawing that shows the change of the polymer structure during heating procedure.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1-1 is a schematic drawing of method of producing a patterned stencil (1) of prior art. The stencil (1) is usually comprised of screen (1-1) polyester of mesh size from 50 mesh to 100 mesh supported on a frame (1-2). Typical method is to draw a pattern (2) on a transparent film (3) of PET (Polyethylene Terephthalate). Then place the film (3) over a stencil (1), on which layer of light sensitive chemical (4) is pasted, and expose to a strong light (5). Then the pattern (2) is projected to the stencil (1) and forms a shadow (2-1) on the stencil (1). Then the light sensitive chemical (4) layer is hardened while the shadow area remains unchanged.

FIG. 1-2 is a schematic drawing of method of prior art producing a patterned fabric (5) grafted clothes (6) utilizing a stencil (1) of prior art. After wash out the unchanged chemical (4) layer, the screen (1-1) mesh is exposed from the shadow (2-1) area of FIG. 1-1. Such, pattern (2) containing, stencil (1) is used for printing a clothes or cutting out patterns from fabrics.

FIG. 1-2 is a schematic drawing of prior art of printing method utilizing stencil. For printing, desired ink (7) is applied to the pattern (2) containing stencil. The ink (7) pass through the mesh (1-1) of the patterned area and print a patterned drawing (2-1) on a clothes (6). The printed clothes (6) can be used as a final product. However, the pattern (2) may fade out by repeated laundry. So, people think about attaching decorated fabrics to clothes by sewing the fabrics directly to the clothes.

FIG. 1-3 is a schematic drawing of method of prior art producing a patterned fabric grafted clothes utilizing a stencil of prior art. A burn out gel (8), which is a mixture of natural alginate, strong acid of printgen® OP-30PS, glycerin and water, is applied to the stencil to cut a patterned patch (2-2) out of a fabric. The cut out patch (2-2) is overlapped on the cloth (6), where the pattern (2) is printed, and is adhered by proper method, sewing is typical. To sew the patch (2-2), the clothes (6) should move to sewing machine. As described above, grafting clothes with patterned patch of fabric by previous method is very cumbersome job.

It is purpose of the current application to provide a simple method to manufacture a durably grafting decorated cotton fabrics to cotton cloths such as blue jeans by gluing. Then, all procedure can be finished with same machines. FIG. 2 is a schematic drawing of gluing and grafting of cotton fabrics (9) to cotton clothes (11) according to current application. And FIG. 3 is the cross sectional view of FIG. 2.

Different from the prior art the procedure of manufacturing a durably grafting decorated cotton fabric to cotton cloths is as follows;

First step is to print a pattern (2) on cotton clothes (11).

Second step is paste a glue solution (10) on the pattern (2) on the cotton clothes (11). Polyone S11111 seriesone clear from Polyone Corporation is used for glue. It contains 1 to 5% of fumed silica for inhibitor.

Third step is to overlap a cotton fabric (9) over the glue (10) pasted clothes (11) such as blue jeans.

Fourth step is to overlap the pattern (2) containing stencil (1) over the front side of the cotton fabric (9).

Fifth step is to place the stencil (1) and clothes (11) between a heating press (13) and press for 5 minutes at 160° C. (320 F.).

Sixth step is to paste the burn out gel (8) on the stencil (1).

Seventh step is to remove the left of burn out from the clothes (11).

All these procedure is done by just stencil and press.

For the above step, the clothes and fabric may be polyester, linen and any other artificial fabrics.

Durability of the glued cotton fabric (9) on clothes (11) is tested by laundering and drying repeatedly. Even after 100 times of machine laundering, the fabric (9) solidly attached to the clothes (11).

No study on the polymer chemistry is done. According to the Polyone's catalogue their Plastisols contains PVC (Polyvinylchloride) resins. Based on the material safety data sheet and catalogue of the Polyone corporation and Sugino, et al.'s U.S. Pat. No. 664', it seems that the plastisol composition of Polyone seems to be a vinyl chloride polymer, a plasticizer and an adhesion-imparting agent, characterized in that the adhesion-imparting agent is a diisocyanate polymer blocked with an oxybenzoic acid ester or with an alkylphenol and having an average molecular weight within a range of from 1,000 to 10,000.

So, when the glue is pasted on the fabrics, it is sol-type oligomer. But, when heat is applied it melts first and penetrates and smeared into the clothes. Then, grafting polymerization occurred. Therefore, the final state of the glue becomes a grafted polymer that is not easily deteriorated by washing and drying at a temperature under 100° C.

FIG. 4 is a schematic drawing that shows the change of the polymer structure during heating procedure. Before heat is applied to the glue (10) is still in linear chains of molecular weight in the range of 1,000 to 10,000. As temperature increases, the oligomer melts and smeared to the clothes (11). As heat is applied continuously, graft polymerization occurs. Then the grafted polymer (10′) layer is formed. Theses grafted polymer (10′) layer provide a durably adhered layer. 

1. A method of durably grafting decorated cotton fabrics to cotton cloths such as Jeans with stencil is comprised of; first step of printing a pattern on a cotton clothes, and second step of pasting a glue solution, Polyone S11111 seriesone clear from Polyone Corporation that contains 1 to 5% of fumed silica for inhibitor, on the pattern on the cotton clothes, and third step of overlapping a cotton fabric over the glue pasted clothes such as blue jeans, and fourth step of overlapping the pattern containing stencil over the front side of the cotton fabric, and fifth step of placing the stencil and clothes between a heating press and press for 5 minutes at 160° C., and sixth step of pasting the burn out gel, which is a mixture of natural alginate, strong acid of printgen® OP-30PS, glycerin and water, on the stencil, and seventh step of removing the left of burn out from the clothes.
 2. A method of durably grafting decorated cotton fabrics to cotton cloths such as Jeans with stencil, in claim 1 wherein, the grafted clothes is durably attached to the cloths even after 100 times of machine laundry.
 3. A method of durably grafting decorated fabrics to cloths with stencil is comprised of; first step of printing a pattern on a cotton clothes, and second step of pasting a glue solution, Polyone S11111 seriesone clear from Polyone Corporation that contains 1 to 5% of fumed silica for inhibitor, on the pattern on the cotton clothes, and third step of overlapping a cotton fabric over the glue pasted clothes such as blue jeans, and fourth step of overlapping the pattern containing stencil over the front side of the cotton fabric, and fifth step of placing the stencil and clothes between a heating press and press for 5 minutes at 160° C., and sixth step of pasting the burn out gel, which is a mixture of natural alginate, strong acid of printgen® OP-30PS, glycerin and water, on the stencil, and seventh step of removing the left of bum out from the clothes.
 4. A method of durably grafting decorated fabrics to cloths with stencil in claim 3, wherein the fabrics is polyester.
 5. A method of durably grafting decorated fabrics to cloths with stencil in claim 3, wherein the clothes is made of polyester.
 6. A method of durably grafting decorated fabrics to cloths with stencil in claim 3, wherein the fabrics is linen.
 7. A method of durably grafting decorated fabrics to cloths with stencil in claim 3, wherein the clothes is made of linen. 